DIY ais removal kit

[solorider]

Has anyone made there own ais kit? In that tapping the head and installing either blanks or bolts,I have just bought a tap and die set from lidl so I thought I could find a use for it

[ghostbiker]

yup did mine the diy way.
Make sure its a good quality tap as well as i snapped a tap off in mine (its still there with chemical metal over the top lol)

[PieEater]

My attempt also didn't go too well so ended up getting a holeshot kit. One thing I know for sure is you need a high quality carbon steel tap, I wouldn't be sure a Lidl special is up to the job.

[Falcon 269]

A good quality tool is important, sure.  That said, I've used Lidl stuff and it's generally pretty good for the money.

More important is to use a tapered tap - for starting threads - rather than a bottoming or plug tap, which are used to finish thread cutting at the bottom of a hole.   The two types are shown here:


I've done several AIS removals using this very tap:



You won't have room to use the tap holder in your Lidl set.  Turn the tap with an open-end spanner instead but be careful to keep the tap vertical and avoid side-loading it as you go.  Obviously you know that you need to grease the tap and wind it back every 1/2 turn to clear swarf.

[justy1]

yeah. i made a few of them in the past.

apart from having to take the rad off, simple to fit. just splodge some gasket silcone in each cap, slide over each spigot do up grub screw (finger tight) & let the silcone set. job done!

would post a pic of um but it seem like ya need a f*ckin degree to post um up!




justy1000

[dekker555]

Hi All, having bin there and dun that, I'd just like to endorse what Falcon 269 Mike says, (OK, I know he's done dozens more than I have, but as it can go wrong, it's worth endorsing) it's important to ensure that that taper tap is VERTICAL by the time it's two threads in. Find yourself a short straight edge, and make sure it is, it far lessens the chance of a broken tap.

[ghostbiker]

if i was doing it again (and if i ever get another fzs1000 i would do it again) then i would use a cap kit like justy's or something rather than tap it. it looks neater and less chance of focing up.

[keithfzs1000]

Why tap when you can use

http://www.ebay.co.uk/itm/230628880619?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

less than 20 english drinking tokens too

[Falcon 269]

Why tap when you can use

http://www.ebay.co.uk/itm/230628880619?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

less than 20 english drinking tokens too

These require you to remove the AIS stub from the exhaust header.  Shrink-fitted by Yamaha, this is not an easy job. 

Just pointing out that this isn't necessarily the simple, cheap solution it appears from the ad. 

[pitternator]

Thats a shame as it looks a neat solution. Just what would be involved in getting such stubs out of the headers mike?
( I still have my AIS...feck ! )

[Falcon 269]

Heat, cold, wrenching, hammering, cussing and prayer.

[PieEater]

If Justy still has some kits left that would be the best route, you pay as much shipping as you do for the Holeshot kit from the US and it's more or less the same thing. If you have the time, experience & patience then you may be able to tap out the spigots but even then you have the concern over where the swarf goes. If you put a value on your time then fitting a kit will probably still work out cheaper than tapping.

[Minty]

Hi, I recently bought the TPO kit and didn't use it in the end as I didn't fancy butchering the spigots out of the exhaust ports.They are pressed in, I believe and after seeing the youtube clip on AIS removal looks like that bloke butchered his. If you can get them out cleanly the TPO kit is perfect for the job. I have taped the spigots and plugged with S/S M8 capheads with some threadlocker/seal. Can be done easily without any kits. Not seen Justys kit but capping is an easy solution also. Hope to fit the TPO kit sometime later if I can find someone who has removed the spigots easily. It makes the top of the engine look so less cluttered when all the pipes are removed.
I used a good quality tap with cutting grease and an old 1/4" square spanner I bought years ago for adjusting drum brakes on cars
Remember them days Drum brakes all round on a car.

[Falcon 269]

No need to worry about swarf from the tap, IMHO.  The vast majority will come out on the grease on the tap.  In the unlikely event that any stays at the bottom of the spigot, it will get burned up and blasted out the headers when you start up.

If it bothers you still, clean out the spigots with a cotton bud after cutting the threads.

[Minty]

Spigots taped and plugged with M8 S/S Capheads.

[Silverdream]

Top job Minty... they look really good...

Did you have much trouble tapping them out?

Well done..

Silverdream